Energy efficiency, sustainability and product safety: Modernisation of the ventilation system for a non-woven fabric manufacturer
Changing production requirements meant that a company in the non-woven fabric industry needed to adapt its existing ventilation system – without replacing the entire plant. Working with airinotec, a modernisation concept was developed which sustainably optimises plant operation through targeted adjustments, intelligent control strategies and energy-efficient drive technology. This made it possible to continue using the existing technology, improve energy efficiency and, at the same time, enhance production reliability.
Initial situation
The existing ventilation system had to be adapted to the changed requirements of production operations. The existing system was already performing several tasks simultaneously, including fibre and dust extraction at the production lines as well as hall exhaust air. The aim was to continue to ensure these functions using the existing ventilation infrastructure whilst also taking into account additional operational and safety requirements. In future, the system was to reliably cover different operating conditions without the need for a complete new investment.
Resource-efficient modernisation rather than new construction
airinotec developed a concept for modernising the existing supply and extract air systems. The focus was on reusing as many existing components as possible whilst bringing the system up to the latest technical standards. In addition to modernising the automation technology, the air flow patterns and individual drive components were adapted to the changed production conditions. This made it possible to continue using the existing infrastructure whilst optimising the system’s performance.
Intelligent control for greater efficiency
A key component of the project was the modernisation of the control technology. The previous control system was replaced by a modern automation solution that regulates supply and extract air according to demand and adapts dynamically to production operations. This ensures a balanced air balance at all times. This not only contributes to energy savings but also protects production processes from the ingress of contaminated air and helps maintain a consistently high product quality. In addition, selected drive components were replaced with energy-efficient motors and the air distribution was adapted to the changed requirements. Supplementary extraction fans improve performance where higher air volumes are required locally. Close coordination between all project stakeholders was a key factor in the success of the implementation.
The modernisation requires a holistic approach. Thanks to the close cooperation of all project stakeholders, a cost-effective and future-proof solution was achieved.
Modernisation requires a holistic approach. Thanks to close cooperation between all those involved in the project, it was possible to implement a cost-effective and future-proof solution.
Long-term benefits for production and operations
Thanks to the modernisation, the production site benefits from more efficient ventilation systems. Energy consumption has been reduced, thereby laying the foundations for permanently lower operating costs. At the same time, the intelligent air balance control system ensures stable production conditions and supports quality assurance. The consistent reuse of existing plant components reduces both resource consumption and the necessary investment costs.
A future-proof solution through targeted modernisation
The project demonstrates what can be achieved by adapting existing ventilation systems to changing production requirements through targeted modernisation measures. Instead of a complete rebuild, a cost-effective and sustainable solution was created that improves energy efficiency, operational reliability and flexibility in equal measure. Regular servicing and maintenance will continue to support the reliable, long-term operation of the modernised system in the future.
